Hinged clip to eliminate rail

ABSTRACT

A panel array support assembly has a lower support joist to which are directly connected panel holding devices or clips. The panel clips are configured so that the length of each clip extends along the length of the lower support joist. The panel clips are preferable configured to have a sliding top arm, which holds the upper edge of the panel, and slides back so that they panel can be placed on a lower holding arm.

PRIORITY INFORMATION

This invention claims priority to U.S. application Ser. No. 12/880,337,filed Sep. 13, 2010, which in turn claims priority to U.S. ProvisionalApplication No. 61/371,370 filed Aug. 6, 2010, making reference to bothdocuments herein in their entireties.

FIELD OF THE INVENTION

This invention relates to support systems for panels and panel-likestructures, such as solar energy collection systems, and moreparticularly to a support system for an array of photovoltaic panels,and a method of quickly assembling the same for activation.

BACKGROUND OF THE INVENTION

Many conventional photovoltaic (solar) panel arrays include a pluralityof solar panels optimally arranged for converting light incident uponthe panels to electricity. Various support systems are used forattachment to roofs, free-field ground racks, tracking units, or othersubstrates/structures. Typically, these support systems are costly,labor-intensive to install, heavy, often structurally inferior, andmechanically complicated. Once the support structure is in place,mounting the solar panels on the support structure can be verydifficult. Further, some large solar panels tend to sag and flex,thereby rendering the panel mounting unstable. Panel repair andadjustment are also rendered more difficult thereby.

A conventional two dimensional panel support system generally includesoff-the-shelf metal framing channels having a C-shaped cross-section,such as those sold under the trademarks UNISTRUT™ or BLIME™. These areimprovised for use as vertical and horizontal support members. Thephotovoltaic (solar) panels 12, or other panel-like structures, aredirectly secured to upper support members (30 in FIG. 3) and held inplace by panel clips or panel holders 45 (as depicted in FIG. 3). Thesepanel clips are found in a wide range of sizes and shapes. The panelclips serve as hold-down devices to secure the panel to thecorresponding top support members (30) in spaced-relationships. Theclips 45 are conventionally positioned and attached about the paneledges once each panel is arranged in place.

In a conventional, free-field ground rack system for mounting solarpanels, as depicted in FIG. 1, vertical support elements, such asI-beams 14, are spaced and securely embedded vertically in the ground.Tilt mounting brackets 16, are installed at the top of each I-beam, andeach tilt mounting bracket is secured to the I-beam such that a tiltbracket flange extends above the I-beam at an angle as best seen in FIG.2A. In this arrangment, two UNISTRUT™ lower joists 20 span the tiltmounting brackets 16 and are secured thereto. As seen in FIG. 2B,UNISTRUT™ rails 30 are positioned across and fastened to lower lowerjoists 20. To secure each rail 30 to the corresponding lower joists 20,a bolt through a bolt hole made in the rail sidewall attaches to athreaded opening in a nut plate (not shown) inserted inside the channelof the UNISTRUT™ joist, so that the nut-like plate engages and tightlysecures against the upper flange of the joist's C-channels as depictedin FIG. 2A.

Once the bi-directional matrix span 10 is assembled, each solar panel 12is secured in place by panel holding clips 45, at least a portion ofwhich are secured to the support rails about the perimeter of eachpanel. At least a portion of the panel clips 45 are put in place, andtightened to support rails 30. This installation process especially ifinvolving multiple clips 45, is often costly, inaccurate, dangerous andtime-consuming.

Another example of a support system for panel like structures is shownin U.S. Pat. No. 5,762,720, issued to Hanoka et al., which describesvarious mounting brackets used with a UNISTRUT™ channel. Notably, theHanoka et al. patent uses a solar cell module having an integralmounting structure, i.e. a mounting bracket bonded directly to a surfaceof the backskin layer of a laminated solar cell module, which is thensecured to the channel bracket by bolts or slideably engaging C-shapedmembers. Other examples of panel support systems are shown in U.S. Pat.No. 6,617,507, issued to Mapes et al.; U.S. Pat. No. 6,370,828, issuedto Genschorek; U.S. Pat. No. 4,966,631, issued to Matlin et al.; andU.S. Pat. No. 7,012,188, issued to Erling. All of these patents areincorporated herein as reference.

Foldable support arrays 10 of upper support rails 30 and lower supportjoists 20 are found in the newer art developed by the inventors of thepresent application. One such example is depicted in FIG. 4. A detailedview of the intersection between upper support rail 30 and lower supportjoist 20 is depicted in FIG. 5. The present inventor have developed anumber of foldable support systems for solar panels and other panel likestructures. These are listed in attached information disclosuredocuments.

The folding support arrays 10 of these support systems solve manyproblems well known in the art of panel array supports. However, evenwith a reliable, easily-deployed support array, there are stilldifficulties in the installation of the panels themselves, especiallysolar panel arrays. In particular, existing support systems requiremeticulous on-site assembly of multiple parts, performed by expensive,dedicated field labor. Assembly is often performed in unfavorableworking conditions, i.e. in harsh weather and over difficult terrain,without the benefit of quality control safeguards and precision tooling.Misalignment of the overall support assembly often occurs, especiallywhen mounting panels to the upper rails 30 with clips 45. This canjeopardize the supported solar panels.

Another problem is the spacing of the photovoltaic (solar) panels 12.This is important to accommodate panel expansion and contraction due tothe change of the weather. It is important, therefore, that the panelsare properly spaced for maximum use of the bi-directional area of thespan. Different panel spacing may be required on account of differenttemperature swings within various geographical areas. It is difficult,however, to precisely space the panels on-site using existing supportstructures and panel clips 45, without advanced (and expensive)technical assistance.

For example, with one of the existing conventional designs describedabove (as depicted in FIGS. 2A and 2B), until the upper rails 30 aretightly secured to the lower support joists 20, each upper rail 30 isfree to slide along the lower support joists 2 and, therefore, will needto be properly spaced and secured once mounted on-site. Further, sincethe distance between the two lower joists 2 is fixed on account of thedrilled bolt holes through the bracket, it is preferred to drill theholes on-site, so that the lower joists can be precisely aligned toattach through the pre-drilled attachment holes of the tilt bracket.Unfortunately, the operation of drilling the holes on-site requiresskilled workers, and even with skilled installation, might still resultin misalignment (i.e. improperly spaced or slightly skewed fromparallel) of the support structure and/or the solar panels supported bythat structure.

An additional degree of difficulty is added by the necessity of drillingholes 145 to accommodate connectors for the panel clips or holders 45.If this is done on site, precise placement of the solar panels becomesextremely difficult. Even if the apertures 145 are precisely drilled atthe factory, an additional degree of imprecision is introduced when thepanel clips 45 have to be connected to the upper support rails 30 whilebeing positioned to hold panels 12. This is an awkward arrangement, evenin the hands of expert installers. Normally, it is accomplished byconnecting one portion of the panel clip 45 to the upper support rail30, and then positioning panel 12 to be secured by another portion ofpanel clip 45. Of necessity, this adds an additional assembly step foreach panel clip 45, while still offering opportunities to accidentlyintroduce misalignment in the overall panel array 10.

Misalignment difficulties are exacerbated by the flexing of the panels12 and sagging permitted by the natural flexibility of the panels. Thesagging of the panels can cause the panels to work out of their holders,whether they would be holding clips or part of the overall structure ofthe upper support rail. Improper installation, which occurs frequentlyin conventional systems, can lead to dislocation of the panels due tosagging or atmospheric conditions. The use of a wide variety ofdifferent mounting positions and panel array arrangements alsoexacerbates the stability problems caused by panel sagging ordeflection. Further, certain mounting positions will make the panels 12more vulnerable to atmospheric disruptions, such as those created bywind and precipitation. All of these variables also complicateelectrical connections to the panels.

One method of correcting misalignment is through the use of larger andmore effective panel clips 45. However, there are drawbacks in thisapproach. In particular, there are only a limited number of points atwhich panel clips can be connected. Accordingly, even with enlargedpanel clips 45, only extremely limited portions of the lengths of panelscan be secured.

The problems of misalignment due to sagging are further exacerbated insome environments by the accumulation ice on the panels. This addsadditional weight without a commensurate structural capability. Icingcan also be a problem due to the tendency of water to work into crevassefound throughout the overall panel array 10. Icing can become particularproblematical with respect to panel clips 45 extending beyond the panels12, or the support rails 30. Accordingly, the use of larger panel clips45 and increased numbers of them have typically added to the problems ofice formation on the overall panel array 10.

Therefore, a need exists for a low-cost, uncomplicated, structurallystrong support system, and assembly method, so as to optimally positionand easily attach the plurality of photovoltaic panels, while meetingarchitectural and engineering requirements. Further, there is an urgentneed for a panel support system that will maintain the security of themechanical connections of the solar panels to support rails despite theflexing of the panels (and support structure) caused by any of gravity,vibration, or environmental factors. Likewise, there is an urgent needto simplify the assembly of panel support systems, especially theconnections between the upper support rails and panel clips. Suchsimplification should not compromise the stability or strength of theconnections between the panels and the support system.

At present, none of the conventional panel support systems offers thesecapabilities. An improved support system would achieve a preciseconfiguration in the field without extensive work at the installationsite. The use of such an improved system would facilitate easy placementof solar panels onto the support structure. The shipping configurationof the improved support system would be such so as to be easily handledin transit while still facilitating rapid deployment. Rapid deploymentmust be facilitated on any type of substrate providing stable supportfor the panels, without damaging or otherwise compromising the panels,or substrate. Rapid deployment would also include rapid mechanicalconnection of the panels using simple panel clips in a manner that wouldkeep the panels secure despite panel flexing, or any number of otherfactors. The preferred system would also minimize ice accumulation onthe panel array, especially at the panel clips.

SUMMARY OF THE INVENTION

It is a primary object of the present invention to improve uponconventional photovoltaic solar panel systems, especially with regard toassembly and installation.

It is another object of the present invention to provide a support andinstallation system for solar panels in which the panels are less likelyto be damaged during installation.

It is a further object of the present invention to provide a simplifiedsupport system for solar panels that is easily installed while stillfacilitating a precise configuration.

It is an additional object of the present invention to provide a solarpanel support system that can be assembled very quickly on site, due tofewer assembly steps.

It is still another object of the present invention to provide a solarpanel support system that can achieve close tolerances during fieldinstallation without the necessity of skilled on-site labor.

It is still an additional object of the present invention to provide asolar panel support system which can be easily adapted to a wide varietyof solar panel array sizes and shapes.

It is yet another object of the present invention to provide a solarpanel support system which minimizes the necessity for precisemeasurements at the installation site.

It is again a further object of the present invention to provide a solarpanel support system that can be arranged at a variety of differentpositions and exposure angles.

It is still an additional object of the present invention to provide asolar panel support system that can be precisely configured to aspecific environment.

It is another object of the present invention to provide a supportsystem for solar panels and other panel-like structures in whichdegradation caused by metal-to-metal contact is substantially reduced.

It is again another object of the present invention to provide a supportsystem for panel-like structures in which accommodation is made formovement caused by changes in temperatures, humidity or otherenvironmental considerations.

It is still a further object of the present invention to provide asimplified connection system for a solar panels using a reduced numberof parts.

It is still an additional object of the present invention to provide asolar panel mounting system that can accommodate easy installation andremoval of panels on adjacent frameworks.

It is yet another object of the present invention to provide a roofinterface framework for a solar panel support structure which allowseasy installation of adjacent panel support systems, without interferingwith previously installed panels.

It is again an additional object of the present invention to provide apanel support system that permits deployment of multiple supportstructures on a wide variety of different substrates.

It is still another object of the present invention to provide a panelsupport system wherein a wide variety of different sizes and shapes ofpanel configurations can be accommodated, and easily installed, as wellas removed.

It is again a further object of the present invention to provide a panelsupport system in which panels can be easily attached to supportbrackets without incurring damage to the panels.

It is still another object of the present invention to provide a supportsystem for panels or panel-like structures for a wide range of uses,positions, and configurations.

It is still a further object of the present invention to provide a panelmounting system which is entirely self-contained with its owninstallation interface.

It is again an additional object of the present invention to provide apanel mounting system which facilitates quick, secure mounting of thepanels once the support system is deployed.

It is yet another object of the present invention to provide a panelsupport system that can accommodate flexing, sagging and otherdeformation of the panels while maintaining a secure connection thereto.

It is yet a further object of the present invention to provide a panelmounting system which facilitates increased panel clip capacity.

It is again an additional object of the present invention to provide apanel mounting system that facilitates safe tightening of panel clips.

It is yet another object of the present invention to provide a panelclip or connector that can accommodate for flexing of both the panel andthe support system.

It is still a further object of the present invention to provide a panelconnection system that can facilitate rapid installation whilemaintaining a secure hold on the panels or panel like structures.

It is yet an additional object of the present invention to providesupport rails configured to ensure a secure panel connection.

It is yet a further object of the present invention to reduce the costof panel support structures by eliminating the overall length ofstructural aluminum, such as those currently used in conventionalsystems, without sacrificing the strength of the overall structure.

It is still an additional object of the present invention to provide apanel support system admitting to substantial flexibility ofconfiguration.

It is again another object of the present invention to provide a panelsupport system which limits ice formation at various parts of the panelarray.

It is again a further object of the present invention to provide a panelsupport system having a profile which limits or avoids overhangingstructures extending from the supported panels.

It is again another objection of the present invention to provide apanel support system that accommodates folding for transport.

It is still an additional object of the present invention to provide apanel support system accommodating protection of panel wiring.

It is yet a further object of the present invention to provide a panelsupport system in which panel clips combine with upper support railsproviding reduced weight for the overall panel support array.

It is again an additional object of the present invention to provide apanel support system including panel clips that are not susceptible toloosening, or allowing panels to shift as occurs with conventionalarrangements having separate support rails and panel support clips.

It is the overall goal of the present invention to provide acomprehensive panel mounting system that facilitates rapid, secureinstallation, including deployment of the panel support structure, andplacement of the panels on that support structure.

These and other goals and objects of the present invention are providedby a panel array support assembly having a lower support joist and anupper panel holding structure detachably mounted to said lower supportjoist, said upper panel holding structure comprising at least oneslideable upper arm arranged to fit over an external panel.

BRIEF DESCRIPTION OF THE DRAWINGS

Having generally described the nature of the invention, reference willnow be made to the accompanying drawings used to illustrate and describethe preferred embodiments thereof. Further, the aforementionedadvantages and others will become apparent to those skilled in this artfrom the following detailed description of the preferred embodimentswhen considered in light of these drawings, in which:

FIG. 1 is a perspective view of an assembled conventional field groundrack support system for securing a plurality of solar panels;

FIG. 2A is a side view of a conventional tilt bracket mount with priorart C-shaped sectional channels secured back-to-back to form supportjoists to which upper support rails, also shown in FIG. 2B, are secured;

FIG. 2B shows an end view of prior art upper support rails, each with aC-shaped sectional channel;

FIG. 3 is a perspective view of a previously-disclosed support system ina configuration as used with solar panels arranged in a column and inspaced relationship thereon;

FIG. 4 is a top view illustrating the bi-directional support framecollapsed to an intermediate folded position;

FIG. 5 is an end elevation and partial sectional view depicting aconventional arrangement of a lower support joist, and upper supportrail, and a panel clip;

FIG. 6A is an end view of a support clip of the present invention, witha sliding arm in a first position;

FIG. 6B is a top view of FIG. 6A;

FIG. 6C is an end view of FIG. 6A with the sliding arm in a second orwithdrawn position;

FIG. 7 is a top view of a section of the sliding arm; and FIG. 8 is aside view depicting a first installed panel and a partially installedsecond panel.

FIG. 8 is a side view of a panel assembly according to the presentinvention.

FIG. 9 is an end view of a second embodiment of the present invention.

FIG. 10 is a side perspective view of a second embodiment of the presentinvention.

FIG. 11 is an end perspective view of a second embodiment of the presentinvention.

FIG. 12 is an end perspective view of the second embodiment of presentinvention, depicting a connection to two external panels.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As has been previously discussed, conventional panel (solar and othertypes) support systems tend to be constituted by two dimensional arrayshaving lower support joists 20 and upper support rails 30. Panel clipsor holders 45 are then field-mounted on the upper support rails so thatthe panels 12 can be placed thereon, and secured with additionalportions of the clips. Even with factory pre-alignment and set up ofsupport joists 20 and upper support raised, conventionally, there islittle that can be done about the many assembly steps required to placeboth the panel clips 45 and the panels on the upper support rails 30.

The present invention, as depicted in FIGS. 6( a-c), 7 and 8, is adeparture from this arrangement. Reinforced clip structure 400, asdepicted in detail by FIGS. 6( a)-6(c), provides a reinforced structureto serve as a clip, and as a substitute for upper support rail 30, suchas that provided in the conventional art previously described herein.This substitution is performed without detriment to the strength andstability of the overall panel array system 10. The structural stabilityof the conventional tubular upper support rail 30 depicted in FIG. 5 isprovided by tubular support structure 405 constituting the main body ofinventive support clip 400. The tubular support structure 405 includestwo side walls 405(a), 405(b), a lower wall 405(c) and an upperthickened wall 405(d). The upper thickened wall 405(d) includes athreaded portion 405(e) to receive an external connecting screw 406.

Inventive reinforced structure clip 400 is held to a conventional lowersupport joist 20 (as depicted in FIG. 8) through the use of a U-shapedstructure, which operates as a slide. This structure includes twoextending legs 402(a), 402(b), which extends on either side of thesidewalls of support joist 20 (not shown in FIG. 6( a & c)). The twoextending legs 402(a), 402(b) are attached to the rest of clip structure400 through horizontal shoulders 401(a), 401(b), respectively. Besidesforming the U-shaped structure to attach clip structure 400, to a lowersupport joist 20, the two shoulder structures 401(a), 401(b) also serveas supports for external panels 12 (as depicted in FIG. 8).

T-slot 409 is provided between shoulders 401(a), 401(b) to accommodate abolt head (not shown) that passes through the lower support joists 20(depicted in FIG. 8). By using T-slot channel 409, the panel clipstructure can be held securely to the lower support joists 20, anadvantage that was not easily achieved in the conventional art where thepanel clip had to be attached separately to the upper support rail 30.By incorporating both the conventional panel clip 45 and theconventional upper support rail 30 into the same structure, (clipstructure 400), the present invention has achieved superior structuralintegrity, as well as greater simplicity. Further, enhanced stability isadded by the extending legs 402(a), 402(b), of the U-shaped structure sothat even greater stability between the two structures (clip structure400 and lower support joists 20) is achieved than has previously beenpossible with the conventional art.

It should be noted that clip structure 400 is preferably made ofaluminum. Conventional support joists 20, upon which the clip structure400 is mounted, are preferably made of steel. Accordingly, provisionmust be made for some kind of barrier to prevent a metal-to-metalcontact between the aluminum clip structure and the steel supportjoists. One way of effecting this is through the use of a nylon gasket(not shown) formed over the interior of the U-shaped structure formed bylegs 402(a), 402(b), and shoulders 401(a) and 401(b). The gasket canhave a hole, to accommodate the bolt (not shown) which will interfacewith T-slot 409. The gasket can be formed of nylon, and be contiguousover the U-shape of the support clip 400. However, other gasketconfigurations and arrangements can be used.

For example, the gasket, or gaskets, can be made to be discontiguous, ina variety of shapes and sizes. Further, while nylon has been proven towork admirably as an insulator, to prevent metal-to-metal contactbetween aluminum and steel, other materials can also be used. Thus,while some type of gasket is necessary between clip structure 400 andsupport joists 20, virtually any arrangement is permissible within theconcept of the present invention.

FIG. 6( b) depicts a top view of support clip 400. Included in the viewis an external tightening screw 406. The entirety of the width ofsupport clip 400 is approximately 1¾ inches. However, while this is onepreferred size, other sizes can be used within the concept of thepresent invention. Also, the length of slip structure 400 is shown to beforeshortened, and contain only a single tightening screw 406. Whilethis is suitable for one embodiment of the present invention, not allembodiments of the present invention are so limited.

In a first embodiment of the present invention, clip structure 400 canbe the approximate length of a conventional clip 45 (as depicted in theconventional art drawings). However, with this configuration, thepresent invention would still suffer from some of the drawbacks of theconventional art. For example, there would still be a very limitednumber of points at which the panels 12 could be connected to anunderlying support array. While this is adequate for some panel supportarrangements 10, this is not always the case.

In another embodiment of the present invention, the length of clipstructure 400 can be much greater than that suggested in FIG. 6( b). Forexample, the length of clip structure 400 can extend for the entirelength of the underlying support joists 20. An appropriate number oftightening screws 406 and accompanying threaded portions could also beprovided based upon the requirements of the specific panel array to bemounted. A continuous connection between the clip structure 400 and thepanel that the clip is holding for a major portion of the length of thatpanel provides a much more secure connection than is currently availablewith conventional art. As a result, many panel flaws and eccentricities(such as sagging, warping, or the like) can be adequately addressed withthe present invention.

Secure, contiguous connections are only part of the advantage providedby the present clip structure 400. The present invention furtheraddresses the difficulties normally occurring with placement andsecuring of panels during the assembly process, and any subsequentrepair or maintenance operations that might require removal oradjustment of panels 12.

In order to appreciate the advantages of the present invention, it isnecessary to consider the parts of clip structure 400 that hold orotherwise interfacing with external panels 12. Normally, the panels 12would rest upon shoulders 401(a) or 401(b). The upper part of the panelwould interface with an upper fixed arm such as 408. In order for clipstructure 400 to hold an external panel 12 using shoulder 401(b) andfixed arm 408, the panel 12 would have to be slid between these twofixed arms. While this may be suitable for one side of the panel, theopposite side would present severe problems if there is an attempt tomount the panel 12 in the same manner. Normally, a panel 12 would haveto be slid perpendicularly (in the Z axis extending out of the drawing)in order to be fit into two fixed panel clips on either side of thepanel where the clip has fixed upper and lower arms, such as shoulder401(b) and fixed arm 408. While this may be practical in somearrangements, it is very often not practical, so that even if thesliding of multiple panels 12 is possible, it can be very awkward.

The problem of mounting and dismounting panels 12 within clip structure400 is solved through the use of hinge or sliding arm 410, a top view ofwhich is depicted in FIG. 7. Sliding arm 410 is attached to the rest ofthe clip structure 400 by means of slot 410(b) and tightening screw 406.This means that the entirety of sliding arm 410 is capable of beingmoved from the position depicted in FIG. 6( a) to the position depictedin FIG. 6( c). In the FIG. 6( c) position, sliding arm 410 is entirelyclear of side wall 405(b). This allows a panel 12 (not shown therein) tobe placed atop shoulder 410(a) from the top of the clip structure 400,rather than being slid sideways.

Movement of sliding arm 410 is controlled through tension generated byspring 407 and tightening screw 406. The spring tension generated canrender movement of sliding arm 410 to be very difficult. This difficultycan be easily overcome by means of beveled shoulder 410(a) which allowssliding arm 410 to slide easily over the top surface of structure405(d). The movement of sliding arm 410 is further facilitated by thebeveled shoulder 408(a) of fixed arm 408. The result of this arrangementis that sliding arm 410 can be effectively controlled so that it can beslid back from its extended position (as depicted in FIG. 6( a)) to aretracted position (as depicted in FIG. 6( c)), and held there withoutany difficulty. Replacement of the sliding arm 410 into its FIG. 6( a)position is easily facilitated by the same structures that permittedeasy sliding and retention in the retracted position. Once sliding arm410 is returned to the extended position (as depicted in FIG. 6( a)),the panel 12 can be tightened in place with little additional effort bysimply operating tightening screw 406 to increase the tension of spring407 on sliding arm 410 (and thus the panel 12 being held firmly bysliding arm 410).

An example of the aforementioned operation is depicted in FIG. 8. Inthis arrangement, lower support joists 20 are arranged on a substrate100 (which can be constituted by any surface from a concrete slab, to aroof, to a metal mounting bracket, for example, atop a tilt bracket foran extended length of joist). The lower support joists 20 are held tothe substrate by any number of different, conventional mountingtechniques, which has been elaborated on in a substantial number ofconventional art examples. Further details of these mounting techniquesare not necessary for an understanding of the present invention.

Multiple clip structures 400 are mounted to the lower support joists 20as previously described, using the U-shaped structure of the lowersupport clip, and if desired, bolts extending through the support joistsand into the T-slot 409 of support clip 400. As depicted in FIG. 8, theright-hand panel 12 has been fit into a first support clip structure400, and the right-hand side of the panel is about to be lowered ontothe far right-hand clip structure 400 from above. The sliding arm 410 ofthe far right-hand support clip 400 has been retracted, and is in thesame position as depicted in FIG. 6( c).

The arrangement depicted in FIG. 8 allows for very easy and rapiddeployment of panels 12, in a wide variety of different configurations.The ease of mounting and dismounting panels 12 for arrangements asdepicted in FIG. 8 renders the installation and maintenance of solarpanel arrays much less expensive than is the prevailing condition forconventional arrays.

A further advantage of the present invention is that the sliding arm 410can be arranged in virtually any length (along the longitude of clipstructure 400) that is considered desirable for a particular panelarray, or even individual panels. Accordingly, a single panel array cancontain any number of different lengths and configurations of slidingarms 410 to better facilitate ease of installation and security of thepanels for a particular place in the panel array, or even a particularpanel. Likewise, because clip structure 400 is arranged parallel to thelower support joists 20, the numbers of tightening screws 406 can bechanged as needed for a particular place or position in the panel array.For example, a three foot length of clip structure 400 could have twofeet of sliding arm 410 arranged at different positions along the lengthof the clip structure 400. The lengths of sliding arm 410 could bemanufactured to have different numbers of slots for increasingly secureconnections between the sliding arm 410 and the panel 12 to be held.

Besides the capability of customizing clip structure 400 for a widevariety of uses, there are other advantages. The increased flexibilityfacilitated by the subject invention is further enhanced by the strengthof tubular structure 405, which provides reinforcement in the holding ofthe panel 12 that cannot be duplicated with conventional arrangements.Even if sliding arm 410 provides only a limited amount of holdingcapability, the side walls of tubular structure 405 hold the panels 12solidly in place. This holding capability limits panel sagging andwarping. The result is a much more stable panel array. This isespecially important when dealing with solar panels.

Another advantage with this embodiment of clip structure 400 is thatthere are far fewer surfaces and other structures for water accumulationand ice formation. By limiting both, the present design reducesenvironmental stresses on the overall panel system and its supports.Since less weight must be supported, money can be saved on underlyingsub straight supports. If the array is deployed on a structure, such asa roof, then there is far less stress on that structure, minimizingchances of structural failure. Of course, to minimize water accumulationand ice formation, the clip structures 400 must be kept quite short inlength. Because of the effectiveness of clip structure 400, only shortlengths are required to securely hold panels 12 in many situationswithout allowing the panels to become loosened. This arrangement issufficiently flexible and adaptable that a wide variety of differentpanel arrangements and environmental conditions can be adequatelyaddressed.

In the embodiments depicted by FIGS. 9 through 12, the combination panelclip/panel rail 500 is also supported by support joists 20 (not shown).These embodiments are depicted as having substantial length, generallyequal to that of panel rails 20 in the conventional art. This isgenerally different from the first group of embodiments (FIGS. 6-8) inwhich the combined panel clip/panel rail 400 is preferably of anabbreviated length. However, it should be noted that the length of clipstructure 500 can be adjusted so as to be shorter than the normal panelrail 20 length found in the conventional art. However, this is often notan optimum arrangement.

The perspective view of FIG. 10 best depicts the variations possiblewith these embodiments with the present invention. The structure asdepicted is a combined panel clip and panel rail 500. In contrast withthe earlier embodiments, there are no U-shaped arms to fit on eitherside of a lower support joist 20. Rather, this group of embodiments usessupport from a support joist 20 (not shown), using a bolt head (notshown) in T slot 509. Because of the greater lengths preferred of clipstructure 500, the U shaped arms of the previous embodiments are notneeded for extra support. Rather, the plurality of bolts (not shown) inT slot 509 is sufficient to hold clip structure 500 to the supportinglower joist 20 (not shown). Preferably, clip structure 500 runs theentire length between two support joists 20 to provide a high level ofstructural support.

Unlike one of the previous embodiments in which a plurality of clipstructures 400 are located along the length of support joist 20, in thepresent embodiments clip structures 500 are contiguous along the entirelength of the span between support joist 20 so that panels 12 are heldsecurely along the entireties of the panel edges facing clip structures500. Further, this support is particularly robust since is effected by acontinuous tubular structure 505 along the panel edges.

The panel clip/rail structure 500 is built on tubular structure 505,which is constituted by two side walls 505(b), 505(a), an upper wall505(d), and a lower wall 505(c). There is additional thickening in atleast a portion of upper wall 505(d) to provide increased stiffness, andin an alternative embodiment to provide a substrate for threading toreceive a screw. Further, the T slot structure 509 adds to the stiffnessof the lower wall 505(c). Enhanced stiffness is also provided by thewiring channel 507. This structure is constituted by an upper wall 501,and a lower wall 502. Both of these structures have angled extensions501(a), 502(a), respectively to help hold the wire within wiring channel507. These angled extensions, 501(a), 502(a), respectively, also provideadditional stiffness along the length of clip structure 500.

On one side of clip structure 500 is a fixed upper arm 508. Parallelthereto is a lower wall 501, constituting the top wall of wiring channel507. The fixed upper arm 508 and the parallel lower wall 501 are spacedapart from with each other so that thickness of a panel 12 can be slidbetween the two. In the effect, the top wall 501 of the wiring channelserves in the same way as shoulder 401(b) (in FIG. 6A) to support thepanel 12 from beneath. The wiring channel 507 and its top wall 501 runthe entire length of clip structure 500.

Preferably, the side wall 505(a) with the fixed upper arm 508 and thetop wall 501 of wiring channel 507 faces an arrangement such as thatseen on the left side of the clip structure 500 in FIG. 10. In thisarrangement, hinge or sliding arm 510 can be slid out of the way so thata panel 12 can be dropped in from above. The panel 12 is supported frombelow by a series of short shelves 503, such as that depicted in FIG.10. The number of shelves 503 can be adjusted based upon the length andweight of panel 12 to be supported, as well as other environmentalconsiderations. The use of the sliding arm 510 on one side of the clipstructure 500 allows installation of panels 12 from above the supportarray, as depicted in FIG. 8.

While the tightening screw 406 and the spring 407 are not depicted inFIGS. 9 through 12, they can nonetheless be used (in an alternativeembodiment) in the same manner as depicted in FIGS. 6A and 6C. However,in the embodiment depicted in FIGS. 9 through 12, the hinge or slidingarm 510 can be secured to the rest of the structure in other ways. Forexample, in one preferred embodiment a slot 511 is formed in the top ofclip structure 500 so that a protrusion 512 in sliding arm 510 caninterface therewith at any point along the length of the clip structure500. Virtually any number of hinges or sliding arms 510 can be slidalong slot 511 to hold a panel 12. Screw slots 510(a) are provided sothat sliding arm 510 can hold the panel 12 to clip structure 500. Thisis done by drilling a screw hole in the top of clip structure 500, or ina framed panel 12.

The structure depicted in FIGS. 9-12 is such that there is very littlesurface on which water can accumulate and form ice. For example, slot511 allows water to drain. The use of intermittent shelves 503 limitslower surfaces on which water can accumulate. Bead 513 on top wall 501prevents water from migrating into the corner of top wall 501 and sidewall 505(a). The angle protrusions 501(a), 502(a) also prevent theaccumulation of water. The top of the structure is substantially flat,with the exception of sliding arm 510. This reduces water accumulationand structures which can accumulate ice. Further, most water falling onthe top of both clip structures 500 and the panels 12 is drained by slot511. As a result, the totality of this arrangement provides ananti-icing configuration.

One advantage of using the sliding arms 510 over those depicted in FIGS.6A and 6C is that the sliding arms 510 do not have to be installed untilafter the panel 12 is put in place. There is no necessity of holdingback a spring-biased sliding arm while the panel 12 is installed fromabove. As a result, the installation technique depicted in FIG. 8,wherein the panel 12 can be installed from above the support array, canbe carried out. This is done by sliding one edge of panel 12 betweenfixed arms (either those depicted in FIG. 6A, 6C, or those depicted inFIGS. 9-12), and then allowing the other end of panel 12 to be placedonto a lower support arm 503 before placing the hinged arms over thenewly placed panel 12. This is much more easily carried out if thehinged arms do not have to be held back against a spring bias.

Further, the number of spring-biased hinged arms (in the FIGS. 6A, 6Cembodiments) is fixed in number. Any addition of hinged arms requiresdrilling and placement of both screws and springs. Deletion requiresthat the screws be removed. Both can be arduous processes during theoverall installation efforts. With the embodiments of FIGS. 9-12, thehinges or sliding arms 510 can be put in place simply by placing aprotrusion 512 into slot 511, and then sliding the sliding arm 510 tothe desired point along the length of clip structure 500. Any number ofsliding arms 510 can be used, based upon the requirements of the panels12 being held and the general environment.

While a number of preferred embodiments have been described by way ofexample, the present invention is not limited thereto. Rather, thepresent invention should be understood to include any and allvariations, modifications, adaptations, permutations, derivations, andembodiments that would occur to one skilled in this art in possession ofthe teachings of the present invention. Accordingly, the presentinvention should be construed to be limited only by the followingclaims.

1. A bi-directional panel array support assembly having at least twolower support joists and at least two upper panel holding structuresrotatably attached to said lower support joists, said upper panelholding structure comprising: a. at least one slidable upper armarranged to extend over a first external panel; and, b. an integralwiring channel.
 2. The bi-directional panel array support assembly ofclaim 1, wherein said upper panel holding structure further comprises atleast one fixed lower arm opposite and parallel to said slidable upperarm, said slidable upper arm and said fixed lower arm being spaced toreceive said first external panel.
 3. The bi-directional panel arraysupport assembly of claim 2, wherein said upper panel holding structurefurther comprises a second set of parallel arms arranged to receive asecond external panel.
 4. The bi-directional panel array supportassembly of claim 3, wherein said second set of parallel arms are fixedand extend perpendicularly to a longitudinal dimension of said upperpanel holding structure and opposite said slidable upper arm.
 5. Thebi-directional panel array support assembly of claim 2, wherein saidupper panel holding structure further comprises a tubular structuresupporting said upper and lower parallel arms.
 6. The bi-directionalpanel array support assembly of claim 5, wherein said slidable upper armis connected to said tubular support structure by a slot extending overthe length of said upper panel holding structure.
 7. The bi-directionalpanel array support assembly of claim 6, said slidable upper arminterfaces with said slot by a closely fitted protrusion on a lower endof said sliding arm.
 8. The bi-directional panel array support assemblyof claim 7, wherein said tubular support structure comprises an upperwall having a thickened area.
 9. The bi-directional panel array supportassembly of claim 8, wherein said tubular support structure comprises abottom wall, said bottom wall comprising a T-slot.
 10. Thebi-directional panel array support assembly of claim 5, wherein a lowerone of said second set of parallel arms comprises an upper wall of saidintegral wiring channel.
 11. The bi-directional panel array supportassembly of claim 10, further comprising an elongated bead on said upperwall of said integral wiring channel, said bead running an entire lengthof said integral wiring channel.
 12. The bi-directional panel arraysupport assembly of claim 11, wherein said integral wiring channelcomprises a lower wall.
 13. The bi-directional panel array supportassembly of claim 12, wherein said upper wall and said lower wall ofsaid integral wiring channel comprises substantially perpendicularprojections.
 14. The bi-directional panel array support assembly ofclaim 12, wherein said upper panel holding structure further comprises aT-slot arranged beneath said tubular structure, wherein an upper wall ofsaid T-slot is comprised by a lower wall of said tubular structure. 15.The bi-directional panel array support assembly of claim 2, wherein saidupper panel holding structure further comprises a plurality of fixedlower arms opposite and parallel to said slidable upper arm.
 16. Thebi-directional panel array support assembly of claim 15, comprising aplurality of slidable arms extended along a length of each said upperpanel holding structure.
 17. The bi-directional panel array supportassembly of claim 1, wherein said panel array support assembly isfoldable from a fully deployed position to a collapsed position.
 18. Amethod of installing panels onto a panel array support assembly fromabove said assembly, said steps comprising: a. deploying said panelarray support assembly to receive said panels; b. placing one end of apanel into two fixed arms of one side of a support structure of saidpanel array support assembly; c. placing an opposite end of said panelon at least one lower arm of a second side of an opposite one of saidsupport structure facing said first support structure; and, d. slidingupper arms along a slot in said second support structure above saidpanel.
 19. A method of claim 18, further comprising the step of: e.screwing said upper arms to said panel.
 20. The method of claim 19,further comprising repeating steps b through d.